US5849113A - Electrical resistant alloy having a high temperature coefficient of resistance - Google Patents

Electrical resistant alloy having a high temperature coefficient of resistance Download PDF

Info

Publication number
US5849113A
US5849113A US08/720,064 US72006496A US5849113A US 5849113 A US5849113 A US 5849113A US 72006496 A US72006496 A US 72006496A US 5849113 A US5849113 A US 5849113A
Authority
US
United States
Prior art keywords
less
alloy
gas
tcr
temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
US08/720,064
Inventor
Yuetsu Murakami
Katashi Masumoto
Naoji Nakamura
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Research Institute of Electric and Magnetic Alloys
Original Assignee
Research Institute of Electric and Magnetic Alloys
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Research Institute of Electric and Magnetic Alloys filed Critical Research Institute of Electric and Magnetic Alloys
Priority to US08/720,064 priority Critical patent/US5849113A/en
Assigned to FOUNDATION: THE RESEARCH INSTITUTE OF ELECTRIC AND MAGNETIC ALLOYS, THE reassignment FOUNDATION: THE RESEARCH INSTITUTE OF ELECTRIC AND MAGNETIC ALLOYS, THE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MASUMOTO, KATASHI, MURAKAMI, YUETSU, NAKAMURA, NAOJI
Application granted granted Critical
Publication of US5849113A publication Critical patent/US5849113A/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Images

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
    • H01C7/06—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material including means to minimise changes in resistance with changes in temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C3/00—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
    • H01C3/04—Iron-filament ballast resistors; Other resistors having variable temperature coefficient

Definitions

  • the present invention relates to an electrical resistant alloy having a high temperature coefficient of resistance, and a method for producing this alloy.
  • the present invention also relates to various sensor devices using this alloy.
  • TCR temperature coefficient of resistance
  • the symbols R s and R c indicate the active resistor for detecting the gas and the standard resistor, respectively.
  • R 1 and R 2 each indicates the balance resistor.
  • the active resistor for detecting gas R s (hereinafter referred to as the active resistor R s ) may be surrounded by a catalyst for oxidation reaction of the gas. Electrical power is supplied from the power source V i to the four resistors R s , R c , R 1 and R 2 .
  • the balance voltage "V" is adjusted to zero with the aid of the variable resistor R c .
  • the active resistor R s and the standard resistor R v are then heated and brought into contact with a gas.
  • the resistance of the active resistor R s is changed by ⁇ R due to the Joule heat generated in it and also due to an oxidation reaction and hence combustion of the gas.
  • the output voltage ⁇ V is generated corresponding to the resistance change ⁇ R and hence to the gas concentration.
  • the output voltage ⁇ V is expressed by:
  • 4R is the total sum of four resistors R s , R c , R 1 and R 2 .
  • the ⁇ R in equation (1) is an index of gas sensitivity and changes depending upon the kind of gas and temperature. When the detecting selectivity of a gas is high, its concentration can be detected by equation (1).
  • FIG. 2 illustrates the output voltage of a gas sensor, in which a Pt filament (40 ⁇ m in diameter) is used as the active resistor R s for detecting gas.
  • the gas sensitivity is high in a temperature range of from 130° to 200° C. for CO gas and in a temperature range of from 200° to 500° C. for hydrogen, ethanol, methane and isobutane. It is therefore necessary that the material selected for the active resistor R s for detecting a specific gas should have a high TCR at a particular temperature range dependent upon the specific gas to be detected as shown in FIG. 2.
  • the catalyst is not attached to the active resistor R s included in a temperature sensor which detects the ambient temperature.
  • the temperature can be precisely detected following equation (1) as also in the case of a gas sensor described hereinabove, since the resistance of the active resistor varies depending on the ambient temperature.
  • pure nickel has a higher TCR than pure Pt.
  • the resistivity of pure nickel is approximately 7 ⁇ .cm and is hence as low as that of pure platinum.
  • the oxidation resistance of pure nickel is poor. Pure nickel is therefore difficult to be practically used as the resistor material from the points described above.
  • phase diagram of an Fe--Pd based alloy is complicated, that is, the stoichiometric compositions, the eutectic phases, the intermediate phases, the ordered structures other than the stoichiometric compositions, e.g., PdFe and FePd 3 formed in a broad range of composition in the phase diagram, and, a magnetic transformation, order-disorder transformation and the like occur in the phase diagram.
  • the Fe--Pd based alloy is easily oxidized.
  • the gas sensor and temperature sensor described above are indispensable in society, for various purposes, such as accident prevention and energy saving. Miniaturization and performance enhancement of such sensors are highly demanded, and such demands are rapidly increasing. Particularly, in recent years, accidents occur frequently involving many victims due to toxious gases, such as carbon monoxide and combustible gas. Not only carbon monoxide gas but also other dangerous gases such as hydrogen (H 2 ), ethanol (C 2 H 5 OH), methane (CH 4 ), isobutane (iC 4 H 10 ) and butane (C 4 H 10 ) may present an important problem to be solved along with the expanded use of city gas and industrial gas in the progress of modernization.
  • a catalytic combustion-type gas sensor has attracted attention in recent years, because of its quick and simple detection of a minor concentration of these toxic gases, its small size, easy handling, high reliability, fast response time, and relatively low price, as compared with another type of gas sensor based on the principle of chemical action.
  • the CO detecting sensitivity is as low as approximately one-tenth or less that of the other gases, e.g., isobutane, and is hence very low. Output voltage variation at a specific gas-concentration is disadvantageously high.
  • a commercially available gas sensor responded to CO gas and another gas, which means poor selectivity of gases. Various disadvantages became therefore apparent in the case of a commercially available CO gas sensor.
  • a platinum coil must be very long so as to obtain high output voltage in the case of a commercially available CO gas sensor. This is the same in a commercially available temperature sensor.
  • the diameter of a pure platinum coil used in the sensors must be as small as 20 ⁇ m or less because of the following reasons.
  • ⁇ R In order to increase the output voltage ⁇ V, ⁇ R must enough high, e.g., 45 ⁇ .
  • ⁇ R is the value of a coil resistor (i.e., active resistor) changed due to the gas combustion
  • R is the resistance of a coil in the sensor
  • ⁇ is a constant determined by the kind of catalyst
  • m is the gas concentration
  • Q is the molecular combustion heat of the gas
  • C is the heat capacity of a sensor.
  • R T1 and R T2 are the electrical resistances at the respective temperatures T1 and T2, respectively. Therefore, the changed value of a coil resistor, ⁇ R, becomes greater as the TCR is greater and the heat capacity is smaller with the proviso that the ⁇ , m and Q are constant in equation (2). This in turn brings about an increase of the output voltage ⁇ V according to equation (1) and hence an increase in the gas sensitivity.
  • the following coefficient of thermal output performance can provide a base for evaluating how a gas- or temperature-sensor can be miniaturized
  • An electrical resistant alloy consisting, by atomic %, of from 5 to 65% of Fe, and from 0.001 to 20% in total, of at least one auxiliary component selected from the group consisting of 20% or less of Ni, 20% or less of Co, 20% or less of Ag, 20% or less of Au, 20% or less of Pt, 10% or less of Rh, 10% or less of Ir, 10% or less of Os, 10% or less of Ru, 10% or less of Cr, 5% or less of V, 5% or less of Ti, 5% or less of Zr, 5% or less of Hf, 8% or less of Mo, 5% or less of Nb, 10% or less of W, 8% or less of Ta, 3% or less of Ga, 3% or less of Ge, 3% or less of In, 3% or less of Be, 5% or less of Sn, 3% or less of Sb, 5% or less of Cu, 5% or less of Al, 5% or less of Si, 2% or less of C, 2% or less of B, and 5% or less of 20% or
  • a catalytic combustion-type gas sensor comprising a bridge circuit, which comprises a standard resistor to be in contact with the gas to be measured, and an active resistor to be contact with the gas to be measured and provided with a catalytic layer, wherein said standard resistor and said active in contact with the gas to be measured, and an active resistor to be contact with the gas to be measured and provided with a catalytic layer, wherein said standard resistor and said active resistor consist of one of the alloys (A) through (H).
  • (P) A catalytic combustion-type gas sensor according to (O), wherein said film is formed by electro-deposition, vapor deposition, ion plating or sputtering.
  • (R) A catalytic combustion-type gas sensor according to (L) through (Q), wherein said gas to be measured is one gas selected from the group consisting of carbon monoxide, hydrogen, ethanol, methane, isobutane and butane.
  • (S) A catalytic combustion-type gas sensor according to (L) through (R), wherein said standard resistor is provided with a coating which comprises at least one compound selected from the group consisting of SiO 2 , Ni 2 O 3 , Al 2 O 3 , CuO, Cr 2 O 3 and TiO 2 .
  • (T) A catalytic combustion-type gas sensor according to (L) through (R), wherein said catalytic layer comprises at least one member selected from the group consisting of Pt black, PdO, Al 2 O 3 , Cu 2 O, ZnO, MnO 2 , Sm 2 O 3 , and Rh 2 O 3 .
  • FIGS. 1(A) and (B) show a bridge circuit used in various sensor devices, in which gas or temperature is detected based on the resistance change depending on the temperature.
  • FIG. 2 is a graph showing the output voltage ⁇ V versus the operating temperature of a sensor and illustrates how a Pt filament used in a gas sensor is sensitive to various gases.
  • FIG. 9 is a graph showing the relationship of TCR of Alloy No. 210 and the heat-treatment temperature.
  • FIG. 10 is a graph showing the relationship of the thickness (d) of the oxide layer of the inventive alloy (Alloy No. 98) and a comparative alloy (Pd--30%Fe--5% Mn) with respect to the heat-treatment temperature (T).
  • FIG. 11 is a graph showing the relationship of the thickness (d) of the oxide layer of the inventive alloy (Alloy No. 210) and a comparative alloy (Pd--30%Fe--5% Mn) with respect to the heat-treatment time.
  • FIG. 12 illustrates a trial-produced CO gas sensor having improved sensitivity (two components).
  • FIG. 13 includes graphs showing the TCR--T (temperature) characteristic and resistivity ⁇ --T characteristic of an inventive alloy (Alloy No. 98) and a comparative material (platinum).
  • FIG. 14 shows TCR--T curves of Alloy Nos. 98, 100, 105, 109, 112 and 117.
  • FIG. 15 includes graphs showing the TCR--T (temperature) characteristic and resistivity ⁇ --T characteristic of an inventive alloy (Alloy No. 210) is used and a comparative CO gas sensor, in which Pt is used.
  • FIG. 16 illustrates the H 2 gas sensitivity characteristic of an H 2 gas sensor, in which an inventive alloy (Alloy No. 210, 213, 225, 232 and 246) is used, and a comparative CO gas sensor, in which Pt is used at sensor temperatures T s .
  • an inventive alloy Alloy No. 210, 213, 225, 232 and 246
  • a comparative CO gas sensor in which Pt is used at sensor temperatures T s .
  • FIG. 17 is a graph showing the output voltage of a CO gas sensor, in which an inventive alloy (Alloy No. 107 or 210) is utilized, with respect to the detected CO gas concentration.
  • FIG. 18 is a graph showing the output voltage ( ⁇ V) of an H 2 gas sensor, in which an inventive alloy (No. 109 or 210) or pure Pt is used.
  • FIG. 19 is a graph showing the output voltage ( ⁇ V) of a temperature sensor in which an inventive alloy (No. 232) or pure Pt is used.
  • the Fe content is limited to a range of from 5 to 65 at %, because outside this range of Fe content, the electrical properties are impaired, although neither oxidation resistance nor formability is impaired.
  • the electrical properties at a high temperature are particularly improved in a high Fe content of from 35 to 65 at %.
  • Mn is added to further improve the electrical properties, the formability and the oxidation resistance.
  • the Mn content is limited to a range of from 0.001 to 20 at % to ensure a high level of electrical properties, formability and oxidation resistance.
  • auxiliary components of the electrical resistant alloys (A) through (C) are described with reference to FIGS. 3 through 5.
  • the auxiliary components i.e., Ni, Co, Ag, Au, Pt, Rh, Ir, Os, Ru, Cr, V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge, In, Be, Sn, Sb, Cu, Al, Si, C, B and a rare-earth element (Sc, Y and lanthanum elements) improve TCR and resistivity.
  • the auxiliary elements also improve the formability of the Pd--Fe alloy.
  • the content of the auxiliary components is kept within the ranges described in the item (A), not only the electrical properties are improved, but also the formability is greatly improved.
  • the improvement in the formability is a synergistic effect of grain-refinement, enhancement of melt-flowability and suppression of oxidation.
  • FIGS. 3 through 5 indicate TCR and resistivity ⁇ of a Pd--33% Fe--alloy with an auxiliary component.
  • TCR and resistivity ⁇ are measured in a temperature range of from 0° to 200° C.
  • the Pd--33%Fe--Me alloy, whose content of the auxiliary component is shown in FIGS. 3 through 5, was in the form of a wire 0.03 mm in diameter and continuously annealed at 1000° C. in hydrogen atmosphere and at 2 m/min of conveying speed.
  • FIGS. 3 through 5 show preferable content and upper limit of the auxiliary elements as follows.
  • Co enhances the magnetic transformation point and hence greatly improves the electrical properties at a high temperature.
  • Co is therefore selected as the first auxiliary component in the electrical resistant alloy (B) mentioned above.
  • TCR is impaired, in addition, the formability is also impaired at a Co content exceeding 20%. Also, TCR and the formability are impaired at an Ni content exceeding 20%.
  • Rh, Ir, Os and Ru are limited as above for the same reasons as described for Co and Ni.
  • the Cr content of 10% or less is effective for forming a continuous oxide layer which prevents further oxidation.
  • Such Cr content is considerably effective for grain-refinement and hence for improving formability. Flowability of melt and formability are seriously impaired at a Cr content higher than 10%.
  • FIG. 4(A) preferable content of V, Ti, or Zr--from about 2 to 4 at %; preferable content of Mo and W from about 2 to 7 at %; the upper limit of V, Ti or Nb--5 at %; upper limit of Mo 8 at %; and the upper limit of W--10 at %.
  • Such elements as V, Ti, Nb and W have functions as described for Cr.
  • the contents of V, Ti, Nb and W are limited as above for the reasons described for Cr.
  • FIG. 4(B) preferable content of Hf or Nb--from about 2 to 3 at %; preferable content of Ta--from about 2 to 5 at %; preferable content of Ga, Ge or In--from about 1 to 2 at %; the upper limit of Hf--5 at %; the upper limit of Ta--8 at %; and the upper limit of Ga, Ge, In or Be--3 at %.
  • Ta, Zr and Hf have functions as described for Cr.
  • the contents of Ta, Hf, Ga, Ge, In and Be are limited as above for the reasons described for Cr.
  • FIG. 5(A) preferable content of Sn, Al, Si, or Cu--from about 3 to 4 at %; preferable content of Sb or Be--from 1 to 2 at %; the upper limit of Sn--5 at %; the upper limit of Cu, Al, Si--5 at %, and the upper limit of Sb--3 at %.
  • Sn at content of 5% or less and Sb at content of 3% or less are effective for forming a continuous oxide layer which prevents further oxidation.
  • Cr and Sb at such contents are considerably effective for grain-refinement and hence for improving formability.
  • Cu, Si and Al have these effects and also improve the flowability of melt, when their contents are limited as above.
  • the contents of Cu, Si and Al described above are effective for suppressing the oxidation and improving the formability.
  • Cu, Si and Al at 5% or less are effective for grain-refinement, improving of melt-flowability and formability, and suppressing the oxidation.
  • FIG. 5(A) preferable content of Cu, Y, La, and Ce--from about 2 to 4%; preferable content of B or C--from about 0.5 to 1.5 at %; the upper limit of Y, La, and Ce--5 at %; and the upper limit of B or C--from about 2 at %.
  • Such elements as C, B and a rare earth element have functions as described for Cu, Si and Al.
  • the contents of C, B and a rare earth element are limited as above for the reasons described for Cu, Si and Al.
  • auxiliary components of the electrical resistant alloys (D) through (E) mentioned above are described with reference to FIGS. 6 through 8.
  • the auxiliary components i.e., Ni, Co, Ag, Au, Pt, Rh, Ir, Os, Ru, Cr, V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge, In, Be, Sn, Sb, Cu, Al, Si, C, B and a rare-earth element (Sc, Y and lanthanum elements) improve TCR, resistivity ⁇ , and formability.
  • the improvement in the formability is a synergistic effect of grain-refinement, enhancement of melt-flowability and suppression of oxidation.
  • FIGS. 6 through 8 indicate TCR and resistivity ⁇ of a Pd--25% Fe--5% Mn--Me alloy. TCR and resistivity ⁇ are measured in a temperature range of from 0° to 200° C. This alloy has been treated by the same method as the Pd 33% Fe--Me alloy.
  • Co is selected as the first auxiliary component in alloy (E).
  • V, Ti, Nb and W are limited as above for the reasons described in item (3), above.
  • FIG. 7(A) preferable content of Zr or Hf--from about 2 to 3 at %; preferable content of Ta--from about 2 to 5 at %; preferable content of Ga, Ge, In or Be--from about 1 to 2 at %; the upper limit of Zr or Hf--5 at %; the upper limit of Ta--8 at %; the upper limit of Ga, Ge, In or Be--3 at %.
  • FIG. 8(A) preferable content of Sn, Al, Si or Cu--from about 3 to 4 at %; preferable content of Sb--from 1 to 2 at %; the upper limit of Sn, Al, Si or Cu--5 at %, and the upper limit of Sb--3 at %.
  • FIG. 8(A) preferable content of Y, La, and Ce--from about 2 to 4%; preferable content of B or C--from about 0.5 to 1.5 at %; the upper limit of Y, La, and Ce--5 at %; and the upper limit of B or C--2 at %.
  • An electrical resistant alloy according to the present invention (No. 210 mentioned below) was formed into a wire having a diameter of 0.03 mm and was annealed in a continuous annealing furnace having a heating zone and cooling zone with appropriate length.
  • the wire was conveyed into the continuous annealing furnace at a conveying speed (V) indicated in the ordinate of FIG. 9.
  • the annealing was carried out in a hydrogen atmosphere at a temperature (T) indicated in the abscissa of FIG. 9.
  • TCR temperature
  • the material of the standard and/or active resistors is annealed at a temperature in a range of from 600° to 1300° C., thereby enhancing TCR and resistivity ⁇ .
  • the annealing in this temperature range decreases the hardness to a level lower than Hv 400, with the result that the formability is further improved.
  • TCR in a range of from 7000-10000 ⁇ 10 -6 ° C. -1 can be attained by continuous annealing at a temperature of from about 800° to 1000° C. and conveying speed of from 2.5 meter/minute or less.
  • An electrical resistant alloy according to the present invention (No. 98 mentioned below) and a comparative alloy (Pd--33% Fe) were formed into a wire having a diameter of 0.5 mm and were then held in ambient air up to 1000° C. for 1 hour (FIG. 10) or at 1000° C. for up to 5 hours (FIG. 11). The wires were then subjected to observation by an optical microscope so as to determine the thickness of the oxide layer.
  • the increase in the oxide layer's thickness of comparative alloy proceeds with the holding time and conforms to a t 1/2 rule.
  • the increase of the oxide layer's thickness (d) inventive alloy conforms to a t 1/3 rule. That is, the thickness (d) of the inventive alloy rapidly increases at the initial holding time but keeps an almost constant value at a holding time of approximately 2 hours or longer. This indicates that a continuous oxide layer is formed on the surface of the inventive alloy at the initial holding time and suppresses subsequent oxidation.
  • the electrical resistance alloys according to the present invention have a continuous oxide layer having a thickness of from 0.01 to 10 ⁇ m, more preferably from 0.05 to 5 ⁇ m.
  • This oxide layer prevents the core part of a filament, strip, wire or the like from oxidation, when a sensor is operated at a temperature higher than 200° C. Since the oxide layer is very thin, it exerts no detrimental effect what ever on the TCR and resistivity characteristic of the inventive alloys.
  • a protective coating is formed on the filament, strip, wire or the like consisting of the inventive alloy, so as to prevent its oxidation.
  • the protective coating may consist of a resin such as polyimide or phenol, a metal such as gold or chromium, or an inorganic compound such as metal oxide or glass. Thickness of the protective layer is preferably from 0.05 to 5 ⁇ m. The protective layer prevents the electrical resistant alloy from oxidation during the gas- or temperature-sensing and can realize the sensing with high sensitivity.
  • the auxiliary component(s) generally refines the crystal grains of a Pd--Fe--(Mn)--Me alloy. Particularly, the auxiliary components except for Ni, Co, Rh, Ga, In, Sn, Sb are effective for the grain refinement.
  • the ingots obtained were forged. Forgeability was good, that is, a small-diameter rod, which is to be subjected to wire drawing, was obtained in a high yield. Since the hot- and cold-formability of the Pd--Fe--(Mn)--Me alloys are improved by the auxiliary elements, the forming process can be simplified and/or omitted such that the number of forging and drawing operations can be reduced.
  • FIG. 12 an embodiment of a gas- or temperature sensor is illustrated.
  • stems 11 protrude through a hermetic substrate 10 and the active component 12 and the standard or compensating component 13 are connected between each pair of stems 11. These components 12 and 13 and the stems 11 are surrounded by a mesh cover 14.
  • the materials used to produce an example of the Pd--Fe--auxiliary component alloy (No. 107) containing 34% of Fe, 5% of Ni, and 3% of Rh, had 99.9% or more purity.
  • the materials 300 g in weight were loaded in an alumina crucible and melted in a high-frequency induction furnace under vacuum. The resultant melt was then thoroughly stirred in the alumina crucible to attain uniformity in the melt. The melt was then poured into a metal mold, whose cavity was 12 mm in diameter and 200 mm in height.
  • the resultant ingot in the form of a round rod was hot-forged and cold-formed by means of a swaging machine and a wire cold-drawing machine, so as to obtain a 0.5 mm diameter wire.
  • the total reduction of area during the cold working is given in Table 1, below. This wire was subjected to various heat treatments under the conditions given in Table 1 and then air cooled. The so-treated wire was used as samples for tests.
  • the samples had a metallic luster except for the samples heat treated in the air atmosphere.
  • the samples were about four to five times as hard as the pure platinum.
  • TCR and resistivity ⁇ of the sample versus temperature (T) are shown in the upper half and lower half of FIG. 13, respectively.
  • the TCR-T characteristic exhibits a peak at a temperature which is coincident with the magnetic transforming point (Tc) of the alloy.
  • the electrical properties at high temperature can be improved by raising the Tc.
  • Example 1 The production process of Example 1 was repeated for treating the inventive alloys Nos. 98, 100, 105, 109, 112 and 117 given in Table 2.
  • TCR in the temperature ranges of from 0° to 200° C., from 0° to 300° C., from 0° to 400° C. and from 0° to 500° C. are given in Table 2.
  • TCR-T characteristic of the samples is shown in FIG. 14. It is apparent that TCR exhibits a peak at the magnetic transformation point (T c ).
  • Example 2 The production process of Example 1 was repeated for treating the inventive alloys Nos. 210, 213, 225, 232 and 246 given in Table 4.
  • TCR in the temperature ranges of from 0° to 200° C., from 0° to 300° C., from 0° to 400° C. and from 0° to 500° C. are given in Table 2.
  • FIGS. 15 and 16 are drawings similar to FIGS. 14 and 15, respectively.
  • the samples also exhibit a peak in the TCR-T curve at the magnetic transforming point (T c ).
  • the 0.5 mm diameter wires (Alloy No. 107 and No. 210) produced in Examples 1 and 3 were further drawn into thin wires having a diameter of 0.03 mm. These wires were finally heat-treated in continuous heat-treating apparatus under a condition of 1000° C. of temperature, hydrogen atmosphere, and 2 m/min of conveying speed. This conveying speed is such that any defect on the wires can be detected by the naked eye. The temperature and gas condition are such that the metallic luster can be maintained and the material is fully softened. The wires were straightened out of the heat-treating apparatus, while being drawn.
  • a thin wire was coiled to provide a coil having a diameter of approximately 1 mm, 25 coiling turns and approximately 10 mm in length. This coil was then connected to electrodes which are 20 mm apart. A pair of the coils, whose TCR and resistance are coincident to one another, was connected to the electrodes and then assembled in a bridge circuit as shown in FIG. 1.
  • a catalyst which is active to gas, i.e., Pt black, PdO, Al 2 O 3 , Cu 2 O, ZnO, MnO 2 , Sm 2 O 3 and Rh 2 O 3 , in the form of slurry was applied on one of the coils.
  • Insulating material which is inactive to gas, i.e., Ni 2 O 3 , Al 2 O 3 , CuO, Cr 2 O 3 and TiO 2 , in the form of slurry was applied on the other coil.
  • the slurries were then dried.
  • the former and latter coils were connected in the circuit shown in FIG. 1(A) as the components 1 and 2, respectively.
  • the bridge voltage Vi was 6V
  • the current through the components 1 and 2 was 40 mA
  • the resistance of each component 1 or 2 was 100 ⁇ .
  • the gas sensitivity is 50 mV at 1000 ppm of CO concentration. This is approximately 27 times as high as a conventional sensor in which pure Pt is used as the coil material.
  • the inventive gas sensor is sensitively responsive to CO gas but is not at all reactive to the other gases, such as city gas, propane or ethylalcohol.
  • the selectivity of the gas is therefore excellent.
  • Example 2 The 0.5 mm diameter wire (Alloy No. 109) produced in Example 1 was further drawn into a thin wire having a diameter of 0.03 mm and was then continuously heat treated by the method described in Example 2.
  • Polyimide coating (5 ⁇ m thick) was applied on one coil, gold was vapor-deposited on another coil (1 ⁇ m thickness) and SiO 2 coating (3 ⁇ m thick) was applied on another coil.
  • a pair of coils, whose coating is one of the above three, and another pair of coils without coating were prepared as described in Example 2.
  • H 2 gas sensors were then manufactured as is described in Example 5.
  • Resistivity of the H 2 gas sensors is shown in FIG. 16.
  • the gas resistivity in terms of the output voltage ( ⁇ V) was: 12 mV at 100° C.; 135 mV at 200° C.; 164 mV at 300° C.; and, 185 mV at 400° C.
  • the resistivity at 400° C. is approximately 26 times as high as that of a conventional sensor, in which Pt is used as the coil material.
  • Example 6 The same coating, manufacturing and test as in Example 6 were carried out with regard to the electrical resistant alloy No. 232. Similar sensitivity as shown in FIG. 16 was attained.
  • the gas resistivity in terms of the output voltage ( ⁇ V) was: 11 mV at 100° C.; 120 mV at 200° C.; 148 mV at 300° C.; and, 170 mV at 400° C.
  • the resistivity at 400° C. is approximately 24 times as high as that of a conventional sensor, in which Pt is used as the coil material.
  • the gas sensor manufactured in Example 6 (Alloy No. 109) was used to detect ethanol, methane, isobutane, and butane.
  • the sensitivity at 1000 ppm of gas concentration is shown in Table 5.
  • the sensitivity of the sensor to the above gases is greatly higher than that of a conventional sensor with the use of a pure Pt.
  • Example 7 The gas sensor manufactured in Example 7 (Alloy No. 232) was used to detect ethanol, methane, isobutane, and butane.
  • the sensitivity at 1000 ppm of gas concentration is shown in Table 6.
  • the sensitivity of the sensor to the above gases is greatly higher than that of a conventional sensor with the use of a pure Pt.
  • Alloy No. 232 was melted, formed and heat-treated as in Example 1 except that, instead of drawing, rolling was carried out to produce a 10 ⁇ m thick and 50 mm wide foil.
  • the foil was then delineated by means of a laser beam to form a pattern shown in FIG. 19 as "B".
  • the delineated foil was then bonded on the insulating substrate A.
  • the delineated foil B on the insulating substrate A was heat-treated as in Example 2.
  • Electrodes C were formed by an electroless plating. On the entire parts A, B and C an SiO 2 coating was deposited by sputtering to 5 nm of thickness.
  • the so treated members A, B and C form an active resistor and a standard resistor of a temperature sensor as shown in FIG. 19 in the present example.
  • the resistors were mounted in a tube shown in FIG. 19.
  • the temperature sensor had 100-1000 ⁇ of resistance.
  • the output from the temperature sensor is shown in FIG. 19.
  • the output of a conventional temperature sensor with the use of pure Pt is shown in FIG. 19. It is clear that the output from the inventive sensor is approximately twice as high as that of the conventional sensor.
  • the Pd--Fe--Me alloys having the compositions as shown in Table 7 were subjected to the same production process as in Example 1, except that the cold-forming was 90%, and, further the heat treatment was 1000° C. for 15 minutes in air followed by air cooling.
  • the resistivity and TCR of the alloys are shown in Table 7.
  • the Pd--Fe--Mn--Me alloys having the compositions as shown in Table 8 were subjected to the same production process as in Example 1, except that the cold-forming was 90%, and, further the heat treatment was 1000° C. for 15 minutes in air followed by air cooling.
  • the resistivity and TCR of the alloys are shown in Table 8.

Landscapes

  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Investigating Or Analyzing Materials By The Use Of Electric Means (AREA)

Abstract

High temperature coefficient of resistance (TCR) appropriate for the sensorevices is attained by an alloy consisting, by atomic %, of from 5 to 65% of Fe, and from 0.01 to 20% in total of at least one auxiliary component selected from the group consisting of 20% or less of Ni, 20% or less of Co, 20% or less of Ag, 20% or less of Au, 20% or less of Pt, 10% or less of Rh, 10% or less of Ir, 10% or less of Os, 10% or less of Ru, 10% or less of Cr, 5% or less of V, 5% or less of Ti, 5% or less of Zr, 5% or less of Hf, 8% or less of Mo, 5% or less of Nb, 10% or less of W, 8% or less of Ta, 3% or less of Ga, 3% or less of Ge, 3% or less of In, 3% or less of Be, 5% or less of Sn, 3% or less of Sb, 5% or less of Cu, 5% or less of Al, 5% or less of Si, 2% or less of C, 2% or less of B, and 5% or less of a rare earth element, the balance being essentially Pd and minor amount of impurities, and said alloy having 4000×10-6° C.-1 or more of TCR in a temperature range of from 0° to 200° C. The alloy may further contain from 5 to 65% of Mn.

Description

BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to an electrical resistant alloy having a high temperature coefficient of resistance, and a method for producing this alloy. The present invention also relates to various sensor devices using this alloy.
2. Description of Related Art
Pure platinum, pure nickel or thermistor, which exhibits a high temperature coefficient of resistance (hereinafter referred to as "TCR"), are conventionally used as an element in a catalytic combustion-type gas sensor and a temperature sensor, in which temperature dependence of the electrical resistance of the pure platinum and the like is utilized to detect gas or temperature. Virtually the same electrical circuit is used in the gas or temperature sensor. Such circuit is illustrated with an example of the gas sensor shown in FIG. 1 which illustrates the principle of a bridge circuit.
In FIG. 1(B), the symbols Rs and Rc indicate the active resistor for detecting the gas and the standard resistor, respectively. R1 and R2 each indicates the balance resistor. The active resistor for detecting gas Rs (hereinafter referred to as the active resistor Rs) may be surrounded by a catalyst for oxidation reaction of the gas. Electrical power is supplied from the power source Vi to the four resistors Rs, Rc, R1 and R2. The balance voltage "V" is adjusted to zero with the aid of the variable resistor Rc. The active resistor Rs and the standard resistor Rv are then heated and brought into contact with a gas. The resistance of the active resistor Rs is changed by ΔR due to the Joule heat generated in it and also due to an oxidation reaction and hence combustion of the gas. As a result, the output voltage ΔV is generated corresponding to the resistance change ΔR and hence to the gas concentration. The output voltage ΔV is expressed by:
ΔV=(ΔR/4R)×V.sub.i                       ( 1)
Here, 4R is the total sum of four resistors Rs, Rc, R1 and R2. The ΔR in equation (1) is an index of gas sensitivity and changes depending upon the kind of gas and temperature. When the detecting selectivity of a gas is high, its concentration can be detected by equation (1).
FIG. 2 illustrates the output voltage of a gas sensor, in which a Pt filament (40 μm in diameter) is used as the active resistor Rs for detecting gas. It is apparent from FIG. 2 that the gas sensitivity is high in a temperature range of from 130° to 200° C. for CO gas and in a temperature range of from 200° to 500° C. for hydrogen, ethanol, methane and isobutane. It is therefore necessary that the material selected for the active resistor Rs for detecting a specific gas should have a high TCR at a particular temperature range dependent upon the specific gas to be detected as shown in FIG. 2.
The catalyst is not attached to the active resistor Rs included in a temperature sensor which detects the ambient temperature. In such a sensor, the temperature can be precisely detected following equation (1) as also in the case of a gas sensor described hereinabove, since the resistance of the active resistor varies depending on the ambient temperature.
It will be understood from the above descriptions that the performance of the above described sensors are greatly influenced by the properties of the active resistor Rs. Pure platinum in the form of a coil has most frequently been used as active resistor Rs, because it has excellent coil-formability, electrical reliance, chemical stability and the like. Pure platinum has approximately 4000×10-6 ° C.-1 of TCR in the temperature range of from 0° to 200° C., approximately 11 μΩ.cm of resistivity and approximately 50 of Vickers hardness. The TCR of pure platinum is lower than the level required for various sensor devices having high sensitivity. In addition, the hardness is also low. Furthermore, platinum is expensive.
Contrary to this, pure nickel has a higher TCR than pure Pt. However, the resistivity of pure nickel is approximately 7 μΩ.cm and is hence as low as that of pure platinum. In addition, the oxidation resistance of pure nickel is poor. Pure nickel is therefore difficult to be practically used as the resistor material from the points described above.
It is known from the literature "Platinum Group and Its Industrial Utilization" (published by Sangyo Tosho Shuppan, page 440) that an Fe--Pd based alloy has a large TCR up to 100° C. The Fe--Pd based alloy is therefore expected to be applicable for a gas sensor or a temperature sensor. However, this alloy disadvantageously is rapidly oxidized, which incurs a serious change in the electrical resistance. The phase diagram of an Fe--Pd based alloy is unknown. Such various points as ρ--T characteristic, formability and oxidation resistance of phases other than Fe3 Pd of the Fe--Pd based alloy remain unknown. The elucidation of these points seems to be difficult, because the phase diagram of an Fe--Pd based alloy is complicated, that is, the stoichiometric compositions, the eutectic phases, the intermediate phases, the ordered structures other than the stoichiometric compositions, e.g., PdFe and FePd3 formed in a broad range of composition in the phase diagram, and, a magnetic transformation, order-disorder transformation and the like occur in the phase diagram. Another reason is that the Fe--Pd based alloy is easily oxidized.
The gas sensor and temperature sensor described above are indispensable in society, for various purposes, such as accident prevention and energy saving. Miniaturization and performance enhancement of such sensors are highly demanded, and such demands are rapidly increasing. Particularly, in recent years, accidents occur frequently involving many victims due to toxious gases, such as carbon monoxide and combustible gas. Not only carbon monoxide gas but also other dangerous gases such as hydrogen (H2), ethanol (C2 H5 OH), methane (CH4), isobutane (iC4 H10) and butane (C4 H10) may present an important problem to be solved along with the expanded use of city gas and industrial gas in the progress of modernization.
A catalytic combustion-type gas sensor has attracted attention in recent years, because of its quick and simple detection of a minor concentration of these toxic gases, its small size, easy handling, high reliability, fast response time, and relatively low price, as compared with another type of gas sensor based on the principle of chemical action.
A commercially available catalytic combustion-type CO gas sensor, in which pure platinum is used as the active detector, was tested by the present inventors. This attained 0.46 mV of ΔV at a 500 ppm of CO concentration. The output voltage ΔV was lower at a lower CO concentration, with the result that the S/N ratio was disadvantageously low. The CO detecting sensitivity is as low as approximately one-tenth or less that of the other gases, e.g., isobutane, and is hence very low. Output voltage variation at a specific gas-concentration is disadvantageously high. In addition to this disadvantage, a commercially available gas sensor responded to CO gas and another gas, which means poor selectivity of gases. Various disadvantages became therefore apparent in the case of a commercially available CO gas sensor. The reason was attributable to the small electrical resistance and small TCR of pure platinum. Another reason was in that, since strength of the pure platinum coil is low, it deforms during application of a catalyst paste thereon and hence the coil pitch varies, which in turn incurs non-uniform temperature distribution on the platinum coil during the current conduction.
A platinum coil must be very long so as to obtain high output voltage in the case of a commercially available CO gas sensor. This is the same in a commercially available temperature sensor. The diameter of a pure platinum coil used in the sensors must be as small as 20 μm or less because of the following reasons. In order to increase the output voltage ΔV, ΔR must enough high, e.g., 45Ω.
When pure Pt having 10 μΩ.cm of resistivity and Pd--Fe alloy having 50 μΩ.cm of resistivity are compared with another, the wire diameter of the former must be smaller than the latter, and the winding number of the former must be greater than the latter as follows.
______________________________________                                    
               Pure Pt                                                    
                     Pd--Fe Alloy                                         
______________________________________                                    
Wire Diameter (μm)                                                     
                 20      30                                               
Diameter of Coil (mm)                                                     
                 0.8     0.8                                              
Winding Number (turn)                                                     
                 45      20                                               
Resistance (Ω)                                                      
                 15      15                                               
______________________________________
It has been expected that these problems can be solved by utilizing a Pd--Fe base alloy having a higher TCR than platinum. However, since the operating temperature of the gas or temperature sensor is relatively high and, further, the oxidation resistance of the Pd--Fe alloy is relatively poor, the sensors involve problems in stability and deterioration of performance. The Pd--Fe alloy is, in addition, difficult to cold work into a fine wire.
The variance in the resistance and TCR in the catalytic combustion-type sensor are expressed, respectively, by equations (2) and (3).
ΔR=α·TCR m Q/c                        (2)
TCR=(R.sub.T2 -R.sub.T1)/(T2-T1)RT.sub.1                   ( 3)
Here, ΔR is the value of a coil resistor (i.e., active resistor) changed due to the gas combustion, R is the resistance of a coil in the sensor, α is a constant determined by the kind of catalyst, m is the gas concentration, Q is the molecular combustion heat of the gas, and C is the heat capacity of a sensor. RT1 and RT2 are the electrical resistances at the respective temperatures T1 and T2, respectively. Therefore, the changed value of a coil resistor, ΔR, becomes greater as the TCR is greater and the heat capacity is smaller with the proviso that the α, m and Q are constant in equation (2). This in turn brings about an increase of the output voltage ΔV according to equation (1) and hence an increase in the gas sensitivity.
The following coefficient of thermal output performance can provide a base for evaluating how a gas- or temperature-sensor can be miniaturized
η=ρ.sup.2 ×TCR                               (4)
The properties of conventional resistor materials, such as pure platinum and thermistor, can therefore be evaluated based on the factors of equations (2) and (4). It can be said that these materials are advantageous according to several evaluations but are detrimental according to other evaluations.
The properties of a resistor material appropriate for gas- or temperature-sensor can be summarized as follows based on the considerations hereinabove.
(a) Average TCR is large.
(b) Resistivity ρ is large.
(c) Coefficient of thermal output performance η, is large.
(d) Secular change or thermal hysteresis of electrical properties is small. When the electrical properties at temperature rise are different from those at temperature fall, that is, the resistor material has hysteresis, the sensitivity of a sensor device fluctuate. Problems in the performance of a sensor device may arise during long use.
(e) Has appropriate hardness Hv such as Fe--Pd alloy.
(f) Has chemical stability.
(g) Is difficult to oxidize.
(h) Has excellent formability so as to obtain a fine wire.
(i) Formability and workability of a coil is excellent.
(j) Is inexpensive.
(k) Variance or fluctuation in the properties (a) through (c) is small.
(l) Defect-free ingots can be obtained.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an novel electrical resistant alloy having improved TCR properties in a temperature range of from 0° to 500° C., more particularly from 0° to 200° C.
It is another object of the present invention to provide a method for producing a fine wire of the electrical resistant alloy.
It is a further object of the present invention to provide a novel sensor device satisfying the properties (a) through (l) mentioned above.
In accordance with an object of the present invention there is provided the following electrical resistant alloys (A) through (H).
(A) An electrical resistant alloy consisting, by atomic %, of from 5 to 65% of Fe, and from 0.001 to 20% in total, of at least one auxiliary component selected from the group consisting of 20% or less of Ni, 20% or less of Co, 20% or less of Ag, 20% or less of Au, 20% or less of Pt, 10% or less of Rh, 10% or less of Ir, 10% or less of Os, 10% or less of Ru, 10% or less of Cr, 5% or less of V, 5% or less of Ti, 5% or less of Zr, 5% or less of Hf, 8% or less of Mo, 5% or less of Nb, 10% or less of W, 8% or less of Ta, 3% or less of Ga, 3% or less of Ge, 3% or less of In, 3% or less of Be, 5% or less of Sn, 3% or less of Sb, 5% or less of Cu, 5% or less of Al, 5% or less of Si, 2% or less of C, 2% or less of B, and 5% or less of a rare earth element, the balance being essentially Pd and a minor amount of impurities, and said alloy having 4000×10-6 ° C.-1 or more of temperature coefficient of resistance in a temperature range of from 0° to 200° C.
(B) An electrical resistant alloy according to (A), wherein Co is selected as the first auxiliary component and at least one element other than Co is selected as the second auxiliary component.
(C) An electrical resistant alloy according to (A), wherein at least one element is selected from the group consisting of Ni, Ag, Au, Pt, Rh, Ir, Os, Ru, Cr, V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge, In, Be, Sn, Sb, Cu, Al, Si, C, B, and a rare earth element.
(D) An electrical resistant alloy consisting, by atomic %, of from 5 to 65% of Fe, from 0.001 to 20% of Mn, and from 0.001 to 20% in total of at least one auxiliary component selected from the group consisting of 20% or less of Ni, 20% or less of Co, 20% or less of Ag, 20% or less of Au, 20% or less of Pt, 10% or less of Rh, 10% or less of Ir, 10% or less of Os, 10% or less of Ru, 10% or less of Cr, 5% or less of V, 5% or less of Ti, 5% or less of Zr, 5% or less of Hf, 8% or less of Mo, 5% or less of Nb, 10% or less of W, 8% or less of Ta, 3% or less of Ga, 3% or less of Ge, 3% or less of In, 3% or less of Be, 5% or less of Sn, 3% or less of Sb, 5% or less of Cu, 5% or less of Al, 5% or less of Si, 2% or less of C, 2% or less of B, and 5% or less of a rare earth element, the balance being essentially Pd and a minor amount of impurities, and said alloy having 4000×10-6 ° C.-1 or more of temperature coefficient of resistance in a temperature range of from 0° to 200° C.
(E) An electrical resistant alloy according to (D), wherein Co is selected as the first auxiliary component and at least one element other than Co is selected as the second auxiliary component.
(F) An electrical resistant alloy according to (D), wherein at least one element is selected from the group consisting of Ni, Ag, Au, Pt, Rh, Ir, Os, Ru, Cr, V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge, In, Be, Sn, Sb, Cu, Al, Si, C, B, and a rare earth element.
(G) An electrical resistant alloy according to (A), (B), (C), (D), (E), or (F), wherein said alloy is in the form of a foil, a thin wire or a ribbon.
(H) An electrical resistant alloy according to (G), wherein said alloy is annealed in a temperature range of from 600° to 1300° C.
In accordance with another object of the present invention there is provided the following methods (I) through (K).
(I) A method for producing an electrical resistance alloy having 4000 or more of temperature coefficient of resistance in a temperature range of from 0° to 200° C., comprising the steps of:
melting in a non-oxidizing gas atmosphere, a reducing gas atmosphere or vacuum, one of the alloys (A) through (H);
casting a resultant melt;
working a material obtained by the casting; and,
annealing said alloy in a temperature range of from 600° to 1300° C.
(J) A method according to (I), wherein said working step comprises hot working and cold working.
(K) A method according to (J), wherein said annealing is carried out by continuous annealing.
In accordance with a further object of the present invention there is provided the following catalytic combustion type sensors (L) through (W).
(L) A catalytic combustion-type gas sensor, comprising a bridge circuit, which comprises a standard resistor to be in contact with the gas to be measured, and an active resistor to be contact with the gas to be measured and provided with a catalytic layer, wherein said standard resistor and said active in contact with the gas to be measured, and an active resistor to be contact with the gas to be measured and provided with a catalytic layer, wherein said standard resistor and said active resistor consist of one of the alloys (A) through (H).
(M) A catalytic combustion-type gas sensor according to (L), wherein said standard resistor and said active resistor are in the form of a foil, a thin wire or a ribbon.
(N) A catalytic combustion-type gas sensor according to (M), wherein at least one of said standard resistor and said active resistor is provided with a coating of metal, resin or inorganic compound on the surface thereof.
(O) A catalytic combustion-type gas sensor according to (M), wherein said standard resistor and said active resistor are in the form of a film formed on an electrically insulating substrate.
(P) A catalytic combustion-type gas sensor according to (O), wherein said film is formed by electro-deposition, vapor deposition, ion plating or sputtering.
(Q) A catalytic combustion-type gas sensor according to (P), wherein said film is delineated by photo-etching or trimming.
(R) A catalytic combustion-type gas sensor according to (L) through (Q), wherein said gas to be measured is one gas selected from the group consisting of carbon monoxide, hydrogen, ethanol, methane, isobutane and butane.
(S) A catalytic combustion-type gas sensor according to (L) through (R), wherein said standard resistor is provided with a coating which comprises at least one compound selected from the group consisting of SiO2, Ni2 O3, Al2 O3, CuO, Cr2 O3 and TiO2.
(T) A catalytic combustion-type gas sensor according to (L) through (R), wherein said catalytic layer comprises at least one member selected from the group consisting of Pt black, PdO, Al2 O3, Cu2 O, ZnO, MnO2, Sm2 O3, and Rh2 O3.
The present invention is hereinafter described with reference to the drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1(A) and (B) show a bridge circuit used in various sensor devices, in which gas or temperature is detected based on the resistance change depending on the temperature.
FIG. 2 is a graph showing the output voltage ΔV versus the operating temperature of a sensor and illustrates how a Pt filament used in a gas sensor is sensitive to various gases.
FIG. 3 includes graphs (A) and (B) showing relationships of resistivity ρ and TCR of Pd--33%Fe--Me (Me=Ni, Co, Ag, Au, Pt, Rh, Ir, Os, Ru or Cr) alloy with respect to the Me concentration.
FIG. 4 includes graphs (A) and (B) showing relationships of resistivity ρ and TCR of Pd--33%Fe--Me (Me=V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge or In) alloy with respect to the Me concentration.
FIG. 5 includes graphs (A) and (B) showing relationships of resistivity ρ and TCR of Pd--33%Fe--Me (Me=Be, Sn, Sb, Cu, Al, Si, C, B, Y, La or Ce) alloy with respect to the Me concentration.
FIG. 6 includes graphs (A) and (B) showing relationships of resistivity ρ and TCR of Pd--25%Fe--5%Mn--Me (Me=Ni, Co, Ag, Au, Pt, Rh, Ir, Os, Ru or Cr) with respect to the Me concentration.
FIG. 7 includes graphs (A) and (B) showing relationships of resistivity ρ and TCR of Pd--25%Fe--5%Mn--Me (Me=V, Ti, Mo, Nb, W, Ta, Ga, Ge, In, Be, Zr or Hf) with respect to the Me concentration.
FIG. 8 includes graphs (A) and (B) showing relationships of resistivity ρ and TCR of Pd--25%Fe--5%Mn--Me (Me=Sn, Sb, Cu, Al, Si, Ce and La) with respect to the Me concentration.
FIG. 9 is a graph showing the relationship of TCR of Alloy No. 210 and the heat-treatment temperature.
FIG. 10 is a graph showing the relationship of the thickness (d) of the oxide layer of the inventive alloy (Alloy No. 98) and a comparative alloy (Pd--30%Fe--5% Mn) with respect to the heat-treatment temperature (T).
FIG. 11 is a graph showing the relationship of the thickness (d) of the oxide layer of the inventive alloy (Alloy No. 210) and a comparative alloy (Pd--30%Fe--5% Mn) with respect to the heat-treatment time.
FIG. 12 illustrates a trial-produced CO gas sensor having improved sensitivity (two components).
FIG. 13 includes graphs showing the TCR--T (temperature) characteristic and resistivity ρ--T characteristic of an inventive alloy (Alloy No. 98) and a comparative material (platinum).
FIG. 14 shows TCR--T curves of Alloy Nos. 98, 100, 105, 109, 112 and 117.
FIG. 15 includes graphs showing the TCR--T (temperature) characteristic and resistivity ρ--T characteristic of an inventive alloy (Alloy No. 210) is used and a comparative CO gas sensor, in which Pt is used.
FIG. 16 illustrates the H2 gas sensitivity characteristic of an H2 gas sensor, in which an inventive alloy (Alloy No. 210, 213, 225, 232 and 246) is used, and a comparative CO gas sensor, in which Pt is used at sensor temperatures Ts.
FIG. 17 is a graph showing the output voltage of a CO gas sensor, in which an inventive alloy (Alloy No. 107 or 210) is utilized, with respect to the detected CO gas concentration.
FIG. 18 is a graph showing the output voltage (ΔV) of an H2 gas sensor, in which an inventive alloy (No. 109 or 210) or pure Pt is used.
FIG. 19 is a graph showing the output voltage (ΔV) of a temperature sensor in which an inventive alloy (No. 232) or pure Pt is used.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the electrical resistant alloys (A) through (H) of the present invention, the Fe content is limited to a range of from 5 to 65 at %, because outside this range of Fe content, the electrical properties are impaired, although neither oxidation resistance nor formability is impaired.
The electrical properties at a high temperature are particularly improved in a high Fe content of from 35 to 65 at %.
In the electrical resistant alloys (D) through (H), Mn is added to further improve the electrical properties, the formability and the oxidation resistance. The Mn content is limited to a range of from 0.001 to 20 at % to ensure a high level of electrical properties, formability and oxidation resistance.
The auxiliary components of the electrical resistant alloys (A) through (C) are described with reference to FIGS. 3 through 5. As is apparent from these drawings, the auxiliary components, i.e., Ni, Co, Ag, Au, Pt, Rh, Ir, Os, Ru, Cr, V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge, In, Be, Sn, Sb, Cu, Al, Si, C, B and a rare-earth element (Sc, Y and lanthanum elements) improve TCR and resistivity. The auxiliary elements also improve the formability of the Pd--Fe alloy. When the content of the auxiliary components is kept within the ranges described in the item (A), not only the electrical properties are improved, but also the formability is greatly improved. The improvement in the formability is a synergistic effect of grain-refinement, enhancement of melt-flowability and suppression of oxidation.
FIGS. 3 through 5 indicate TCR and resistivity ρ of a Pd--33% Fe--alloy with an auxiliary component. TCR and resistivity ρ are measured in a temperature range of from 0° to 200° C. The Pd--33%Fe--Me alloy, whose content of the auxiliary component is shown in FIGS. 3 through 5, was in the form of a wire 0.03 mm in diameter and continuously annealed at 1000° C. in hydrogen atmosphere and at 2 m/min of conveying speed.
FIGS. 3 through 5 show preferable content and upper limit of the auxiliary elements as follows.
(1) FIG. 3 (A): preferable content of Ni, Pt, Ag, Co or Au--from about 4 to 12 at %, and the upper limit of Ni, Pt, Ag, Co or Au--20 at %.
Co enhances the magnetic transformation point and hence greatly improves the electrical properties at a high temperature.
Co is therefore selected as the first auxiliary component in the electrical resistant alloy (B) mentioned above. However, TCR is impaired, in addition, the formability is also impaired at a Co content exceeding 20%. Also, TCR and the formability are impaired at an Ni content exceeding 20%.
(2) FIG. 3 (B): preferable content of Rh, Ir, Os, Ru or Cr--from about 3 to 8 at %, and the upper limit of Rh, Ir, Os, Ru or Cr--10 at %.
The contents of Rh, Ir, Os and Ru are limited as above for the same reasons as described for Co and Ni. The Cr content of 10% or less is effective for forming a continuous oxide layer which prevents further oxidation. Such Cr content is considerably effective for grain-refinement and hence for improving formability. Flowability of melt and formability are seriously impaired at a Cr content higher than 10%.
(3) FIG. 4(A): preferable content of V, Ti, or Zr--from about 2 to 4 at %; preferable content of Mo and W from about 2 to 7 at %; the upper limit of V, Ti or Nb--5 at %; upper limit of Mo 8 at %; and the upper limit of W--10 at %.
Such elements as V, Ti, Nb and W have functions as described for Cr. The contents of V, Ti, Nb and W are limited as above for the reasons described for Cr.
(4) FIG. 4(B): preferable content of Hf or Nb--from about 2 to 3 at %; preferable content of Ta--from about 2 to 5 at %; preferable content of Ga, Ge or In--from about 1 to 2 at %; the upper limit of Hf--5 at %; the upper limit of Ta--8 at %; and the upper limit of Ga, Ge, In or Be--3 at %.
Ta, Zr and Hf have functions as described for Cr. The contents of Ta, Hf, Ga, Ge, In and Be are limited as above for the reasons described for Cr.
(5) FIG. 5(A): preferable content of Sn, Al, Si, or Cu--from about 3 to 4 at %; preferable content of Sb or Be--from 1 to 2 at %; the upper limit of Sn--5 at %; the upper limit of Cu, Al, Si--5 at %, and the upper limit of Sb--3 at %.
Sn at content of 5% or less and Sb at content of 3% or less are effective for forming a continuous oxide layer which prevents further oxidation. Cr and Sb at such contents are considerably effective for grain-refinement and hence for improving formability. Cu, Si and Al have these effects and also improve the flowability of melt, when their contents are limited as above. The contents of Cu, Si and Al described above are effective for suppressing the oxidation and improving the formability.
Cu, Si and Al at 5% or less are effective for grain-refinement, improving of melt-flowability and formability, and suppressing the oxidation.
(6) FIG. 5(A): preferable content of Cu, Y, La, and Ce--from about 2 to 4%; preferable content of B or C--from about 0.5 to 1.5 at %; the upper limit of Y, La, and Ce--5 at %; and the upper limit of B or C--from about 2 at %.
Such elements as C, B and a rare earth element have functions as described for Cu, Si and Al. The contents of C, B and a rare earth element are limited as above for the reasons described for Cu, Si and Al.
The auxiliary components of the electrical resistant alloys (D) through (E) mentioned above are described with reference to FIGS. 6 through 8. As is apparent from these drawings, the auxiliary components, i.e., Ni, Co, Ag, Au, Pt, Rh, Ir, Os, Ru, Cr, V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge, In, Be, Sn, Sb, Cu, Al, Si, C, B and a rare-earth element (Sc, Y and lanthanum elements) improve TCR, resistivity ρ, and formability. The improvement in the formability is a synergistic effect of grain-refinement, enhancement of melt-flowability and suppression of oxidation.
FIGS. 6 through 8 indicate TCR and resistivity ρ of a Pd--25% Fe--5% Mn--Me alloy. TCR and resistivity ρ are measured in a temperature range of from 0° to 200° C. This alloy has been treated by the same method as the Pd 33% Fe--Me alloy.
(7) FIG. 6 (A): preferable content of Ni, Pt, Ag, Co or Au--from about 3 to 9 at %, and the upper limit of Ni, Pt, Ag, Co or Au--20 at %.
Since Co enhances the magnetic transformation point and hence greatly improves the electrical properties at a high temperature, Co is selected as the first auxiliary component in alloy (E).
The reasons for limiting the Ni, Pt, Ag, Co and Au contents are the same as in item (1), above.
(8) FIG. 6 (A): preferable content of Rh, Ir, Os, Ru or Cr--from about 3 to 8 at %; and the upper limit of Rh, Ir, Os, Ru or Cr--10 at %.
The contents of Pt, Ag, Au, Rh, Ir, Os and Ru are limited as above for the same reasons as described in item (2) above.
(9) FIG. 7 (A): preferable content of V, Ti or Nb--from about 2 to 4 at %, preferable content of Mo from about 2 to 7 at %; preferable content of W--from 2 to 7 at %; the upper limit of V, Ti or Nb--5 at %; the upper limit of Mo 8 at %; and the upper limit of W--10 at %.
The contents of V, Ti, Nb and W are limited as above for the reasons described in item (3), above.
(10) FIG. 7(A): preferable content of Zr or Hf--from about 2 to 3 at %; preferable content of Ta--from about 2 to 5 at %; preferable content of Ga, Ge, In or Be--from about 1 to 2 at %; the upper limit of Zr or Hf--5 at %; the upper limit of Ta--8 at %; the upper limit of Ga, Ge, In or Be--3 at %.
The contents of Ta, Zr, Hf, Ga, Ge, In and Be are limited as above for the reasons described item (4), above.
(11) FIG. 8(A): preferable content of Sn, Al, Si or Cu--from about 3 to 4 at %; preferable content of Sb--from 1 to 2 at %; the upper limit of Sn, Al, Si or Cu--5 at %, and the upper limit of Sb--3 at %.
The contents of Sn, Al, Si and Cu are limited for the reasons described in item (5), above.
(12) FIG. 8(A): preferable content of Y, La, and Ce--from about 2 to 4%; preferable content of B or C--from about 0.5 to 1.5 at %; the upper limit of Y, La, and Ce--5 at %; and the upper limit of B or C--2 at %.
The contents of Y, La, Ce, C, B and a rare earth element are limited as above for the reasons described in item (6).
An electrical resistant alloy according to the present invention (No. 210 mentioned below) was formed into a wire having a diameter of 0.03 mm and was annealed in a continuous annealing furnace having a heating zone and cooling zone with appropriate length. The wire was conveyed into the continuous annealing furnace at a conveying speed (V) indicated in the ordinate of FIG. 9. The annealing was carried out in a hydrogen atmosphere at a temperature (T) indicated in the abscissa of FIG. 9. As is apparent from FIG. 9, very high TCR can be obtained by appropriately selecting the conveying speed (V) and the heat-treatment temperature (T).
Similar curves as shown in FIG. 9 were obtained with regard to the Pd--34% Fe--5% Ni--3% Rh alloy.
According to an embodiment of the present invention, based on the discoveries involved in FIG. 9, the material of the standard and/or active resistors is annealed at a temperature in a range of from 600° to 1300° C., thereby enhancing TCR and resistivity ρ. The annealing in this temperature range decreases the hardness to a level lower than Hv 400, with the result that the formability is further improved.
According to another embodiment of the present invention, TCR in a range of from 7000-10000×10-6 ° C.-1 can be attained by continuous annealing at a temperature of from about 800° to 1000° C. and conveying speed of from 2.5 meter/minute or less.
An electrical resistant alloy according to the present invention (No. 98 mentioned below) and a comparative alloy (Pd--33% Fe) were formed into a wire having a diameter of 0.5 mm and were then held in ambient air up to 1000° C. for 1 hour (FIG. 10) or at 1000° C. for up to 5 hours (FIG. 11). The wires were then subjected to observation by an optical microscope so as to determine the thickness of the oxide layer.
The increase in the oxide layer's thickness of comparative alloy (FIG. 11) proceeds with the holding time and conforms to a t1/2 rule. The increase of the oxide layer's thickness (d) inventive alloy (FIG. 11) conforms to a t1/3 rule. That is, the thickness (d) of the inventive alloy rapidly increases at the initial holding time but keeps an almost constant value at a holding time of approximately 2 hours or longer. This indicates that a continuous oxide layer is formed on the surface of the inventive alloy at the initial holding time and suppresses subsequent oxidation.
Similar curves as shown in FIG. 10 and 11 were obtained with regard to the Pd--25% Fe--5% Mn--5% Ni--5% Pt alloy (No. 210 mentioned below).
According to a preferred embodiment of the present invention, based on the discovery shown in FIGS. 10 and 11, the electrical resistance alloys according to the present invention have a continuous oxide layer having a thickness of from 0.01 to 10 μm, more preferably from 0.05 to 5 μm. This oxide layer prevents the core part of a filament, strip, wire or the like from oxidation, when a sensor is operated at a temperature higher than 200° C. Since the oxide layer is very thin, it exerts no detrimental effect what ever on the TCR and resistivity characteristic of the inventive alloys.
According to another preferred embodiment of the present invention, a protective coating is formed on the filament, strip, wire or the like consisting of the inventive alloy, so as to prevent its oxidation. The protective coating may consist of a resin such as polyimide or phenol, a metal such as gold or chromium, or an inorganic compound such as metal oxide or glass. Thickness of the protective layer is preferably from 0.05 to 5 μm. The protective layer prevents the electrical resistant alloy from oxidation during the gas- or temperature-sensing and can realize the sensing with high sensitivity.
The flowability of a Pd--Fe--(Mn)--Me melt was investigated in a casting process. Materials from 100 to 300 g in weight were melted in a high-frequency induction furnace, and poured into ingots. Metal flow into the metallic ingot case, the metal amount left in the crucible, and defects on the ingots resulting from metal-flow failure were observed. The alloys with the addition of Ni, Co, Rh, Au, Ga, In, Sn, Sb, Cu, Si or B exhibited more remarkably improved flowability than with other auxiliary elements.
The auxiliary component(s) generally refines the crystal grains of a Pd--Fe--(Mn)--Me alloy. Particularly, the auxiliary components except for Ni, Co, Rh, Ga, In, Sn, Sb are effective for the grain refinement.
The ingots obtained were forged. Forgeability was good, that is, a small-diameter rod, which is to be subjected to wire drawing, was obtained in a high yield. Since the hot- and cold-formability of the Pd--Fe--(Mn)--Me alloys are improved by the auxiliary elements, the forming process can be simplified and/or omitted such that the number of forging and drawing operations can be reduced.
Referring to FIG. 12, an embodiment of a gas- or temperature sensor is illustrated. Four stems 11 protrude through a hermetic substrate 10 and the active component 12 and the standard or compensating component 13 are connected between each pair of stems 11. These components 12 and 13 and the stems 11 are surrounded by a mesh cover 14.
The present invention is hereinafter described by way of examples.
EXAMPLE 1
The materials used to produce an example of the Pd--Fe--auxiliary component alloy (No. 107) containing 34% of Fe, 5% of Ni, and 3% of Rh, had 99.9% or more purity. The materials 300 g in weight were loaded in an alumina crucible and melted in a high-frequency induction furnace under vacuum. The resultant melt was then thoroughly stirred in the alumina crucible to attain uniformity in the melt. The melt was then poured into a metal mold, whose cavity was 12 mm in diameter and 200 mm in height. The resultant ingot in the form of a round rod was hot-forged and cold-formed by means of a swaging machine and a wire cold-drawing machine, so as to obtain a 0.5 mm diameter wire. The total reduction of area during the cold working is given in Table 1, below. This wire was subjected to various heat treatments under the conditions given in Table 1 and then air cooled. The so-treated wire was used as samples for tests.
The samples had a metallic luster except for the samples heat treated in the air atmosphere. The samples were about four to five times as hard as the pure platinum.
TCR and resistivity ρ of the sample versus temperature (T) are shown in the upper half and lower half of FIG. 13, respectively. The TCR-T characteristic exhibits a peak at a temperature which is coincident with the magnetic transforming point (Tc) of the alloy. The electrical properties at high temperature can be improved by raising the Tc.
                                  TABLE 1                                 
__________________________________________________________________________
Cold Heat Treatment                                                       
Work-                                                                     
     Tempera-     Resis-       Hard-                                      
ing  ture Time                                                            
              Atmos-                                                      
                  tivity ρ ness                                       
                                  Sur-                                    
(%)  (°C.)                                                         
          (min)                                                           
              phere                                                       
                  0° C.                                            
                      200° C.                                      
                          TCR  (Hv)                                       
                                  face                                    
__________________________________________________________________________
90   --   --  --  32  58.2                                                
                          4250 470                                        
                                  Fine                                    
                                  wrought                                 
                                  struc-                                  
                                  ture                                    
90    800 30  air 51  139.2                                               
                          8680 260                                        
                                  Slightly                                
                                  oxidized                                
                                  Light gray                              
90   1000 60  air 53  162.2                                               
                          10300                                           
                               190                                        
                                  Uniform                                 
                                  oxide                                   
                                  film                                    
70    800 120 Hydro-                                                      
                  51  139.2                                               
                          8930 265                                        
                                  Metallic                                
              gen                 luster                                  
70   1000 60  Hydro-                                                      
                  55  171.6                                               
                          10600                                           
                               200                                        
                                  Metallic                                
              gen                 luster                                  
70   1200 30  Hydro-                                                      
                  52  161.2                                               
                          10500                                           
                               185                                        
                                  Metallic                                
              gen                 luster                                  
80    800 120 Argon                                                       
                  49  135.8                                               
                          8860 265                                        
                                  Slightiy                                
                                  oxidized                                
                                  Light                                   
                                  gray                                    
80   1000 120 Argon                                                       
                  49  135.8                                               
                          8860 265                                        
                                  Slightly                                
                                  oxidized                                
                                  Light                                   
                                  gray                                    
__________________________________________________________________________
 Remarks: TCR is in 10.sup.-6 ° C..sup.-1. Resistivity is          
 μΩ · cm.
EXAMPLE 2
The production process of Example 1 was repeated for treating the inventive alloys Nos. 98, 100, 105, 109, 112 and 117 given in Table 2. TCR in the temperature ranges of from 0° to 200° C., from 0° to 300° C., from 0° to 400° C. and from 0° to 500° C. are given in Table 2.
              TABLE 2                                                     
______________________________________                                    
Composition (at %)                                                        
               TCR (10.sup.-6 ° C..sup.-1)                         
Alloy      Auxiliary                 0-    0-                             
No.  Fe    components  0-200° C.                                   
                              0-300° C.                            
                                     400° C.                       
                                           500° C.                 
______________________________________                                    
98   34    Ni = 5, Rh = 3                                                 
                       10600  --     --    --                             
100  40    Ru = 2, Y = 1                                                  
                       9900   11000  --    --                             
105  48    Ta = 2, Hf = 0.5                                               
                       9300   10350  10450 --                             
109  50    Cr = 2, Co = 9                                                 
                       8800   9750   10750 11800                          
112  55    W = 3, Nb = 1                                                  
                       7950   8800   9700  --                             
117  60    Pt = 2, Si = 0.5                                               
                       7500   8300   9150  --                             
______________________________________
The TCR-T characteristic of the samples is shown in FIG. 14. It is apparent that TCR exhibits a peak at the magnetic transformation point (Tc).
EXAMPLE 3
An alloy (No. 210), which contained 25% of Fe, 5% of Mn, 5% of Ni and 5% of Pt, the balance being Pd and impurities, was melted, formed and heat-treated by the same methods as in Example 1. The resistivity ρ, TCR, hardness and surface condition of the samples are shown in Table 3.
                                  TABLE 3                                 
__________________________________________________________________________
Cold Heat Treatment                                                       
Work-                                                                     
     Tempera-     Resis-       Hard-                                      
ing  ture Time                                                            
              Atmos-                                                      
                  tivity ρ ness                                       
                                  Sur-                                    
(%)  (°C.)                                                         
          (min)                                                           
              phere                                                       
                  0° C.                                            
                      200° C.                                      
                          TCR  (Hv)                                       
                                  face                                    
__________________________________________________________________________
95   --   --  --  30   57  4580                                           
                               450                                        
                                  Fine                                    
                                  wrought                                 
                                  struc-                                  
                                  ture                                    
95    800 30  air 48  130  8520                                           
                               270                                        
                                  Liqht                                   
                                  gray                                    
90   1000 60  air 52  165 10900                                           
                               200                                        
                                  Uniform                                 
                                  oxide                                   
                                  film                                    
75    800 120 Hydro-                                                      
                  46  127  8760                                           
                               275                                        
                                  Metallic                                
              gen                 luster                                  
75   1000 60  Hydro-                                                      
                  50  162 11160                                           
                               205                                        
                                  Metallic                                
              gen                 luster                                  
75   1200 30  Hydro-                                                      
                  51  160 10730                                           
                               195                                        
                                  Metallic                                
              gen                 luster                                  
85    800 120 Argon                                                       
                  47  128  8640                                           
                               277                                        
                                  Slightly                                
                                  oxidized                                
                                  Light                                   
                                  gray                                    
85   1000 60  Argon                                                       
                  51  161 10810                                           
                               203                                        
                                  Slightly                                
                                  oxidized                                
                                  Light                                   
                                  gray                                    
__________________________________________________________________________
EXAMPLE 4
The production process of Example 1 was repeated for treating the inventive alloys Nos. 210, 213, 225, 232 and 246 given in Table 4. TCR in the temperature ranges of from 0° to 200° C., from 0° to 300° C., from 0° to 400° C. and from 0° to 500° C. are given in Table 2.
              TABLE 4                                                     
______________________________________                                    
Composition (at %)                                                        
                TCR (10.sup.-6 ° C..sup.-1)                        
Alloy            Auxiliary 0-    0-    0-    0-                           
No.  Fe    Mn    components                                               
                           200° C.                                 
                                 300° C.                           
                                       400° C.                     
                                             500° C.               
______________________________________                                    
210  34    5     Ni = 5, Pt = 5                                           
                           10900 --    --    --                           
213  42    7     Pt = 2, Zr = 1                                           
                           9850  11150 --    --                           
225  47    4     Ge = 2, Cr = 2                                           
                           8850  10050 10400 --                           
232  52    3     Ru = 2, Co = 10                                          
                           8100  9100  10250 11600                        
246  60    8     W = 3, Nb = 1                                            
                           7700  8750   9850 --                           
______________________________________
FIGS. 15 and 16 are drawings similar to FIGS. 14 and 15, respectively. The samples also exhibit a peak in the TCR-T curve at the magnetic transforming point (Tc).
EXAMPLE 5
The 0.5 mm diameter wires (Alloy No. 107 and No. 210) produced in Examples 1 and 3 were further drawn into thin wires having a diameter of 0.03 mm. These wires were finally heat-treated in continuous heat-treating apparatus under a condition of 1000° C. of temperature, hydrogen atmosphere, and 2 m/min of conveying speed. This conveying speed is such that any defect on the wires can be detected by the naked eye. The temperature and gas condition are such that the metallic luster can be maintained and the material is fully softened. The wires were straightened out of the heat-treating apparatus, while being drawn.
A thin wire was coiled to provide a coil having a diameter of approximately 1 mm, 25 coiling turns and approximately 10 mm in length. This coil was then connected to electrodes which are 20 mm apart. A pair of the coils, whose TCR and resistance are coincident to one another, was connected to the electrodes and then assembled in a bridge circuit as shown in FIG. 1.
A catalyst, which is active to gas, i.e., Pt black, PdO, Al2 O3, Cu2 O, ZnO, MnO2, Sm2 O3 and Rh2 O3, in the form of slurry was applied on one of the coils. Insulating material, which is inactive to gas, i.e., Ni2 O3, Al2 O3, CuO, Cr2 O3 and TiO2, in the form of slurry was applied on the other coil. The slurries were then dried. The former and latter coils were connected in the circuit shown in FIG. 1(A) as the components 1 and 2, respectively.
Referring to FIG. 17 the gas-sensitivity of a gas sensor produced as above is shown. The bridge voltage Vi was 6V, the current through the components 1 and 2 was 40 mA, and the resistance of each component 1 or 2 was 100Ω. The gas sensitivity is 50 mV at 1000 ppm of CO concentration. This is approximately 27 times as high as a conventional sensor in which pure Pt is used as the coil material.
The inventive gas sensor is sensitively responsive to CO gas but is not at all reactive to the other gases, such as city gas, propane or ethylalcohol. The selectivity of the gas is therefore excellent.
EXAMPLE 6
The 0.5 mm diameter wire (Alloy No. 109) produced in Example 1 was further drawn into a thin wire having a diameter of 0.03 mm and was then continuously heat treated by the method described in Example 2. Polyimide coating (5 μm thick) was applied on one coil, gold was vapor-deposited on another coil (1 μm thickness) and SiO2 coating (3 μm thick) was applied on another coil. A pair of coils, whose coating is one of the above three, and another pair of coils without coating were prepared as described in Example 2. H2 gas sensors were then manufactured as is described in Example 5.
Resistivity of the H2 gas sensors is shown in FIG. 16. The test conditions of the gas sensors were: bridge voltage Vi =2V; current through the components=40 mA; resistance=200Ω, =100Ω, =60Ω, and 35Ω (no coating); and the temperature of components (Ts)=100° C., 200° C., 300° C. and 400° C.
The gas resistivity in terms of the output voltage (ΔV) was: 12 mV at 100° C.; 135 mV at 200° C.; 164 mV at 300° C.; and, 185 mV at 400° C. The resistivity at 400° C. is approximately 26 times as high as that of a conventional sensor, in which Pt is used as the coil material.
EXAMPLE 7
The same coating, manufacturing and test as in Example 6 were carried out with regard to the electrical resistant alloy No. 232. Similar sensitivity as shown in FIG. 16 was attained. The gas resistivity in terms of the output voltage (ΔV) was: 11 mV at 100° C.; 120 mV at 200° C.; 148 mV at 300° C.; and, 170 mV at 400° C. The resistivity at 400° C. is approximately 24 times as high as that of a conventional sensor, in which Pt is used as the coil material.
EXAMPLE 8
The gas sensor manufactured in Example 6 (Alloy No. 109) was used to detect ethanol, methane, isobutane, and butane. The sensitivity at 1000 ppm of gas concentration is shown in Table 5.
              TABLE 5                                                     
______________________________________                                    
       Output Voltage (ΔV)-mV at 1000 ppm                           
Kind of                                                                   
       of Gas Concentration                                               
of Gas 100° C.                                                     
                 200° C.                                           
                         300° C.                                   
                                 400° C.                           
                                       500° C.                     
______________________________________                                    
Ethanol                                                                   
       10        80      98      122   147                                
(C.sub.2 H.sub.5 OH)                                                      
Methane                                                                   
       --        --      --       96   118                                
(CH.sub.4)                                                                
Isobutane                                                                 
       --        --      --      158   183                                
(iC.sub.4 H.sub.10)                                                       
Butane --        --      --      135   172                                
(C.sub.4 H.sub.10)                                                        
______________________________________
The sensitivity of the sensor to the above gases is greatly higher than that of a conventional sensor with the use of a pure Pt.
EXAMPLE 9
The gas sensor manufactured in Example 7 (Alloy No. 232) was used to detect ethanol, methane, isobutane, and butane. The sensitivity at 1000 ppm of gas concentration is shown in Table 6.
              TABLE 6                                                     
______________________________________                                    
       Output Voltage (ΔV)-mV at 1000 ppm                           
Kind of                                                                   
       of Gas Concentration                                               
of Gas 100° C.                                                     
                 200° C.                                           
                         300° C.                                   
                                 400° C.                           
                                       500° C.                     
______________________________________                                    
Ethanol                                                                   
       6         64      77      92    108                                
(C.sub.2 H.sub.5 OH)                                                      
Methane                                                                   
       --        --      --      85     97                                
(CH.sub.4)                                                                
Isobutane                                                                 
       --        --      --      136   158                                
(iC.sub.4 H.sub.10)                                                       
Butane --        --      --      127   146                                
(C.sub.4 H.sub.10)                                                        
______________________________________
The sensitivity of the sensor to the above gases is greatly higher than that of a conventional sensor with the use of a pure Pt.
EXAMPLE 10
Alloy No. 232 was melted, formed and heat-treated as in Example 1 except that, instead of drawing, rolling was carried out to produce a 10 μm thick and 50 mm wide foil. The foil was then delineated by means of a laser beam to form a pattern shown in FIG. 19 as "B". The delineated foil was then bonded on the insulating substrate A. The delineated foil B on the insulating substrate A was heat-treated as in Example 2. Electrodes C were formed by an electroless plating. On the entire parts A, B and C an SiO2 coating was deposited by sputtering to 5 nm of thickness. The so treated members A, B and C form an active resistor and a standard resistor of a temperature sensor as shown in FIG. 19 in the present example. The resistors were mounted in a tube shown in FIG. 19. The temperature sensor had 100-1000Ω of resistance.
The output from the temperature sensor is shown in FIG. 19. For comparison purposes, the output of a conventional temperature sensor with the use of pure Pt is shown in FIG. 19. It is clear that the output from the inventive sensor is approximately twice as high as that of the conventional sensor.
Another inventive temperature sensor with the use of Alloy No. 109 attained virtually the same results as those of the above inventive sensor.
EXAMPLE 11
The Pd--Fe--Me alloys having the compositions as shown in Table 7 were subjected to the same production process as in Example 1, except that the cold-forming was 90%, and, further the heat treatment was 1000° C. for 15 minutes in air followed by air cooling. The resistivity and TCR of the alloys are shown in Table 7.
              TABLE 7                                                     
______________________________________                                    
                                  TCR                                     
Alloy Composition (at %)                                                  
                       Resistivity                                        
                                  10.sup.-6 ° C..sup.-1,           
No.   Fe    Auxiliary components                                          
                           (μΩ · cm).°C.         
                                    0-200° C.                      
______________________________________                                    
7     35    Ni 8           50       10200                                 
12    20    Co 10          55       9750                                  
18    25    Ag 6           56       8700                                  
25    30    Au 8           57       8400                                  
31    42    Pt 8           55       8900                                  
37    33    Rh 7           53       9100                                  
44    50    Ir 7           50       8200                                  
49    15    Os 12          57       8850                                  
54    27    Ru 7           50       8200                                  
57    38    Cr 4           50       8200                                  
63    40    V 3            53       8100                                  
68    25    Ti 2           54       7900                                  
74    30    Zr 3           56       8450                                  
79    38    Hf 2           49       8000                                  
83    22    Mo 4           54       8300                                  
86    40    Nb 2           50       8250                                  
90    35    W 4            52       9150                                  
94    27    Ta 4           51       8950                                  
98    34    Ni 5, Rh 3     55       10600                                 
103   40    Cu 3, Be I     56       8100                                  
107   30    W 5, Pt 3      58       9800                                  
115   22    Al 1, In 1     56       8800                                  
120   35    Ru 6, Au 2     63       9900                                  
124   24    Ta 5, Ga 1     58       9500                                  
129   36    Si 1, Mo 2     57       9200                                  
132   40    V 2, Sb 1      55       8750                                  
138   35    Y 3, Hf 2, Sn 1                                               
                           66       9500                                  
144    8    Nb 2, La 1, C 0.3                                             
                           48       8900                                  
150   60    W 3, B 0.3, Rh 2                                              
                           56       10100                                 
155   33    Zr 2, Ru 5, Ce 1                                              
                           59       9800                                  
Comparative material                                                      
                   10.6       3867                                        
Pt (Pure platinum)                                                        
______________________________________                                    
 Remarks: Balance of Fe and auxiliary compounds is Pd.
EXAMPLE 12
The Pd--Fe--Mn--Me alloys having the compositions as shown in Table 8 were subjected to the same production process as in Example 1, except that the cold-forming was 90%, and, further the heat treatment was 1000° C. for 15 minutes in air followed by air cooling. The resistivity and TCR of the alloys are shown in Table 8.
              TABLE 8                                                     
______________________________________                                    
                                    TCR                                   
Alloy                                                                     
     Composition (at %) Resistivity 10.sup.-6 ° C.sup.-1,          
No.  Fe    Mn     Auxiliary Components                                    
                              (μΩ · cm).°C.      
                                        0-200° C.                  
______________________________________                                    
5    25    5      Ni 5        46        10700                             
8    35    10     Ni 15       54        9420                              
15   55    5      Co 5        52        7650                              
20   30    10     Co 10       55        8900                              
25   20    10     Az 3        45        9100                              
28   40    5      Ag 12       48        8260                              
35   25    7      Au 4        48        8810                              
40   35    3      Au 13       46        8370                              
45   15    5      Pt 5        49        8860                              
50   30    10     Pt 10       47        9530                              
55   20    8      Rh 2        50        9210                              
60   15    10     Ir 3        52        8680                              
65   25    3      Os 1        48        9050                              
70   30    7      Ru 3        51        9240                              
75   10    15     Cr 5        55        8580                              
80   25    10     V 2         50        8400                              
85   35    5      Ti 2        47        8260                              
90   20    10     Zr 3        49        8630                              
95   30    5      Hr 3        47        8800                              
100  15    10     Mo 2        52        9030                              
105  25    7      Hb 2        50        8620                              
110  20    10     H 5         54        9100                              
115  35    5      Ta 4        48        9260                              
120  50    3      Ga 1        47        7820                              
125  15    10     Ge 1        52        7960                              
130  35    5      In 1        45        8080                              
135  25    3      Be 1        45        8260                              
140  20    10     Sn 1        53        8350                              
145  35    5      Sb 1        48        8190                              
150  25    3      Cu 2        48        8630                              
155  30    5      Al 1.5      47        9760                              
160  40    10     Si 1.5      55        9020                              
165  15    10     C 0.5       59        7630                              
170  30    5      B 0.3       57        7870                              
175  25    8      Y 2         49        9220                              
180  20    10     La 2        53        8700                              
185  30    5      Ce 2        48        8460                              
200  40    10     Ni 5, Co 5  55        9150                              
210  25    5      Ni 5, Pt 5  52        10900                             
220  40    5      Au 5, Ag 5  49        9030                              
230  30    10     Rh 2, Ti 1  57        9570                              
240  20    5      Ir 2, Cr 1, Nb 1                                        
                              48        9310                              
250  35    3      Os 2, V 2, Ga 1                                         
                              47        8830                              
260  25    8      Ru 1, In 1, Sb 1                                        
                              52        8960                              
270  20    10     Zr 2, Al 1, Sn 1                                        
                              55        9470                              
280  35    3      Hf 2, Be 1, Si 1                                        
                              53        9590                              
290  30    5      Mo 2, Y 1, Cu 1                                         
                              53        9360                              
300  15    10     Pt 5, Ge 1, C 0.5                                       
                              56        9770                              
310  40    5      Ag 5, La 2, B 0.5                                       
                              52        9360                              
320  20    10     Au 3, Ta 5, Al 1                                        
                              55        8850                              
330  35    10     Ru 2, Ti 1, W 2, Si 1                                   
                              57        8930                              
340  25    5      Pt 3, Rh 2, Zr 1, Cu 2                                  
                              50        9160                              
Compara-                                                                  
       Pt (Pure platinum)                                                 
                        10.6        3867                                  
tive                                                                      
Material                                                                  
______________________________________

Claims (8)

We claim:
1. An electrical resistant alloy consisting, by atomic %, of from 5 to 65% of Fe, and from 0.01 to 20% in total of at least one auxiliary component selected from the group consisting of 20% or less of Ni, 20% or less of Co, 20% or less of Ag, 3 to 9% of Au, 20% or less of Pt, 10% or less of Rh, 10% or less of Ir, 10% or less of Os, 10% or less of Ru, 10% or less of Cr, 5% or less of V, 5% or less of Ti, 5% or less of Zr, 5% or less of Hf, 8% or less of Mo, 5% or less of Nb, 10% or less of W, 8% or less of Ta, 3% or less of Ga, 3% or less of Ge, 3% or less of In, 3% or less of Be, 5% or less of Sn, 3% or less of Sb, 5% or less of Cu, 5% or less of Al, 5% or less of Si, 2% or less of C, 2% or less of B, and 5% or less of a rare earth element, the balance being essentially Pd and a minor amount of impurities, said alloy being an annealed alloy and having 4000×10-6 ° C.-1 or more of temperature coefficient of resistance in a temperature range of from 0° to 200° C.
2. An electrical resistant alloy according to claim 1, wherein Co is selected as a first auxiliary component and at least one element other than Co is selected as a second auxiliary element.
3. An electrical resistant alloy according to claim 1, wherein said at least one element is selected from the group consisting of Ni, Ag, Au, Pt, Rh, Ir, Os, Ru, Cr, V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge, In, Be, Sn, Sb, Cu, Al, Si, C, B, and a rare earth element.
4. An electrical resistant alloy consisting, by atomic %, of from 5 to 65% of Fe, from 5 to 65% of Mn, and from 0.01 to 20% in total of at least one auxiliary component selected from the group consisting of 20% or less of Ni, 20% or less of Co, 20% or less of Ag, 3 to 9% of Au, 20% or less of Pt, 10% or less of Rh, 10% or less of Ir, 10% or less of Os, 10% or less of Ru, 10% or less of Cr, 5% or less of V, 5% or less of Ti, 5% or less of Zr, 5% or less of Hf, 8% or less of Mo, 5% or less of Nb, 10% or less of W, 8% or less of Ta, 3% or less of Ga, 3% or less of Ge, 3% or less of In, 3% or less of Be, 5% or less of Sn, 3% or less of Sb, 5% or less of Cu, 5% or less of Al, 5% or less of Si, 2% or less of C, 2% or less of B, and 5% or less of a rare earth element, the balance being essentially Pd and a minor amount of impurities, said alloy being an annealed alloy and having 4000×10-6 ° C.-1 or more of temperature coefficient of resistance in a temperature range of from 0° to 200° C.
5. An electrical resistant alloy according to claim 4, wherein Co is selected as a first auxiliary component and at least one element other than Co is selected as a second auxiliary element.
6. An electrical resistant alloy according to claim 4, wherein said at least one element is selected from the group consisting of Ni, Ag, Au, Pt, Rh, Ir, Os, Ru, Cr, V, Ti, Zr, Hf, Mo, Nb, W, Ta, Ga, Ge, In, Be, Sn, Sb, Cu, Al, Si, C, B, and a rare earth element.
7. An electrical resistant alloy according to claim 1, 2, 3, 4 or 5, wherein said alloy is in the form of a foil, thin wire or a ribbon.
8. An electrical resistant alloy according to claim 7, wherein said alloy is annealed in a temperature range of from 600° to 1300° C.
US08/720,064 1996-09-27 1996-09-27 Electrical resistant alloy having a high temperature coefficient of resistance Expired - Fee Related US5849113A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US08/720,064 US5849113A (en) 1996-09-27 1996-09-27 Electrical resistant alloy having a high temperature coefficient of resistance

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US08/720,064 US5849113A (en) 1996-09-27 1996-09-27 Electrical resistant alloy having a high temperature coefficient of resistance

Publications (1)

Publication Number Publication Date
US5849113A true US5849113A (en) 1998-12-15

Family

ID=24892492

Family Applications (1)

Application Number Title Priority Date Filing Date
US08/720,064 Expired - Fee Related US5849113A (en) 1996-09-27 1996-09-27 Electrical resistant alloy having a high temperature coefficient of resistance

Country Status (1)

Country Link
US (1) US5849113A (en)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6531226B1 (en) 1999-06-02 2003-03-11 Morgan Chemical Products, Inc. Brazeable metallizations for diamond components
US20040074285A1 (en) * 2002-10-17 2004-04-22 Dimeo Frank Apparatus and process for sensing fluoro species in semiconductor processing systems
US20040163444A1 (en) * 2002-10-17 2004-08-26 Dimeo Frank Nickel-coated free-standing silicon carbide structure for sensing fluoro or halogen species in semiconductor processing systems, and processes of making and using same
US20040163445A1 (en) * 2002-10-17 2004-08-26 Dimeo Frank Apparatus and process for sensing fluoro species in semiconductor processing systems
US20040187557A1 (en) * 2002-10-17 2004-09-30 Chen Philip S.H. Apparatus and process for sensing target gas species in semiconductor processing systems
US20080134757A1 (en) * 2005-03-16 2008-06-12 Advanced Technology Materials, Inc. Method And Apparatus For Monitoring Plasma Conditions In An Etching Plasma Processing Facility
CN100494459C (en) * 2005-09-19 2009-06-03 丹阳市龙鑫合金有限公司 Electric resistance alloy and its preparing process
CN102277524A (en) * 2010-06-13 2011-12-14 厦门鑫柏龙仪器仪表有限公司 Au-Fe-Ni-Cr alloy
US20130299562A1 (en) * 2011-01-14 2013-11-14 Sabastian Piegert Cobalt-based alloy comprising germanium and method for soldering
CN108950378A (en) * 2018-06-06 2018-12-07 江苏大印电子科技有限公司 A kind of wear-resistant high-intensitive bus duct

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3136634A (en) * 1962-02-02 1964-06-09 Degussa Noble metal alloys having a high specific electric resistance
US4481045A (en) * 1979-10-31 1984-11-06 The Foundation: The Research Institute Of Electric And Magnetic Alloys High-coercive-force permanent magnet with a large maximum energy product and a method of producing the same
JPS60204847A (en) * 1984-03-28 1985-10-16 Res Inst Electric Magnetic Alloys Constant electric resistance alloy, production thereof and sensor using said alloy
US4728580A (en) * 1985-03-29 1988-03-01 The Standard Oil Company Amorphous metal alloy compositions for reversible hydrogen storage

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3136634A (en) * 1962-02-02 1964-06-09 Degussa Noble metal alloys having a high specific electric resistance
US4481045A (en) * 1979-10-31 1984-11-06 The Foundation: The Research Institute Of Electric And Magnetic Alloys High-coercive-force permanent magnet with a large maximum energy product and a method of producing the same
JPS60204847A (en) * 1984-03-28 1985-10-16 Res Inst Electric Magnetic Alloys Constant electric resistance alloy, production thereof and sensor using said alloy
US4728580A (en) * 1985-03-29 1988-03-01 The Standard Oil Company Amorphous metal alloy compositions for reversible hydrogen storage

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6531226B1 (en) 1999-06-02 2003-03-11 Morgan Chemical Products, Inc. Brazeable metallizations for diamond components
US7296460B2 (en) 2002-10-17 2007-11-20 Advanced Technology Materials, Inc. Apparatus and process for sensing fluoro species in semiconductor processing systems
US7080545B2 (en) 2002-10-17 2006-07-25 Advanced Technology Materials, Inc. Apparatus and process for sensing fluoro species in semiconductor processing systems
US7228724B2 (en) * 2002-10-17 2007-06-12 Advanced Technology Materials, Inc. Apparatus and process for sensing target gas species in semiconductor processing systems
US20040187557A1 (en) * 2002-10-17 2004-09-30 Chen Philip S.H. Apparatus and process for sensing target gas species in semiconductor processing systems
US20050199496A1 (en) * 2002-10-17 2005-09-15 Dimeo Frank Jr. Apparatus and process for sensing fluoro species in semiconductor processing systems
US20050205424A1 (en) * 2002-10-17 2005-09-22 Dimeo Frank Jr Apparatus and process for sensing fluoro species in semiconductor processing systems
US20050230258A1 (en) * 2002-10-17 2005-10-20 Dimeo Frank Jr Apparatus and process for sensing fluoro species in semiconductor processing systems
US8109130B2 (en) 2002-10-17 2012-02-07 Advanced Technology Materials, Inc. Apparatus and process for sensing fluoro species in semiconductor processing systems
US20040163445A1 (en) * 2002-10-17 2004-08-26 Dimeo Frank Apparatus and process for sensing fluoro species in semiconductor processing systems
US20040074285A1 (en) * 2002-10-17 2004-04-22 Dimeo Frank Apparatus and process for sensing fluoro species in semiconductor processing systems
US7475588B2 (en) 2002-10-17 2009-01-13 Advanced Technology Materials, Inc. Apparatus and process for sensing fluoro species in semiconductor processing systems
US20040163444A1 (en) * 2002-10-17 2004-08-26 Dimeo Frank Nickel-coated free-standing silicon carbide structure for sensing fluoro or halogen species in semiconductor processing systems, and processes of making and using same
US20080134757A1 (en) * 2005-03-16 2008-06-12 Advanced Technology Materials, Inc. Method And Apparatus For Monitoring Plasma Conditions In An Etching Plasma Processing Facility
CN100494459C (en) * 2005-09-19 2009-06-03 丹阳市龙鑫合金有限公司 Electric resistance alloy and its preparing process
CN102277524A (en) * 2010-06-13 2011-12-14 厦门鑫柏龙仪器仪表有限公司 Au-Fe-Ni-Cr alloy
CN102277524B (en) * 2010-06-13 2013-04-24 厦门鑫柏龙仪器仪表有限公司 Au-Fe-Ni-Cr alloy
US20130299562A1 (en) * 2011-01-14 2013-11-14 Sabastian Piegert Cobalt-based alloy comprising germanium and method for soldering
US8763885B2 (en) * 2011-01-14 2014-07-01 Siemens Aktiengesellschaft Cobalt-based alloy comprising germanium and method for soldering
CN108950378A (en) * 2018-06-06 2018-12-07 江苏大印电子科技有限公司 A kind of wear-resistant high-intensitive bus duct

Similar Documents

Publication Publication Date Title
JP4296344B2 (en) Copper alloy material
US5849113A (en) Electrical resistant alloy having a high temperature coefficient of resistance
US4064757A (en) Glassy metal alloy temperature sensing elements for resistance thermometers
EP1108796B1 (en) Nickel based article containing chromium, boron and silicon and production process
CN109055823A (en) Novel high-resistance electrothermic alloy Cr20Ni80Al and preparation method thereof
US4518439A (en) Alloy with small change of electric resistance over wide temperature range and method of producing the same
US3974001A (en) Paramagnetic alloy
JP3696310B2 (en) Electrical resistance alloy having large temperature coefficient of resistance, manufacturing method thereof and sensor device
JP3696312B2 (en) Electrical resistance alloy having large temperature coefficient of resistance, manufacturing method thereof and sensor device
JP5408533B2 (en) Fe-Ni-Cr-based isoelastic composition for strain gauge, and strain gauge manufactured using the composition
US4374679A (en) Electrical resistant article having a small temperature dependence of electric resistance over a wide temperature range and a method of producing the same
JPH10280069A (en) Electric resistance alloy having high resistance temperature coefficient, its production and sensor device
JPS60204847A (en) Constant electric resistance alloy, production thereof and sensor using said alloy
JPH11193426A (en) Electric resistance alloy, its production and sensor device
JP2810242B2 (en) Pd-Fe-based electric resistance alloy having large temperature coefficient of resistance and heat output performance index, method for producing the same, and sensor device
JPH11195504A (en) Electrical resistance thin-film and manufacture thereof and sensor device
JPH11512216A (en) High temperature resistant metal material and method of manufacturing the same
JP4895481B2 (en) Resistance thin film and sputtering target for forming the resistance thin film
JP2659716B2 (en) Alloy having low temperature coefficient of electric resistance and low melting point, method for producing the same, and highly stable electric resistor or eddy current displacement sensor using the same
EP1327694A1 (en) Electric resistance element and raw material for the same and method for preparing the same
JP2524883B2 (en) Contact combustion type CO gas sensor and its manufacturing method
JPS596345A (en) Alloy reduced in change of electric resistance over wide temperature range and preparation thereof
JPH0317895B2 (en)
JPS6253585B2 (en)
JP4283954B2 (en) Constant temperature resistance alloy for high temperature and high pressure, its manufacturing method and sensor

Legal Events

Date Code Title Description
FEPP Fee payment procedure

Free format text: PAYOR NUMBER ASSIGNED (ORIGINAL EVENT CODE: ASPN); ENTITY STATUS OF PATENT OWNER: SMALL ENTITY

AS Assignment

Owner name: FOUNDATION: THE RESEARCH INSTITUTE OF ELECTRIC AN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:MURAKAMI, YUETSU;MASUMOTO, KATASHI;NAKAMURA, NAOJI;REEL/FRAME:008414/0267;SIGNING DATES FROM 19961229 TO 19970107

FPAY Fee payment

Year of fee payment: 4

FPAY Fee payment

Year of fee payment: 8

REMI Maintenance fee reminder mailed
LAPS Lapse for failure to pay maintenance fees
STCH Information on status: patent discontinuation

Free format text: PATENT EXPIRED DUE TO NONPAYMENT OF MAINTENANCE FEES UNDER 37 CFR 1.362

FP Lapsed due to failure to pay maintenance fee

Effective date: 20101215